Issue link: https://read.dmtmag.com/i/378880
What is remanufacturing? A properly "rebuilt" spare part is the functional equivalent of a new part and is virtually indistinguishable from a new part. In fact, the Federal Trade Commission (FTC) requires that such parts be labeled as "rebuilt" so they are not mistakenly accepted as new. For all practical purposes, remanufacturing injectors is very much like assembling new parts except that many of the components are taken from previously used parts, especially the housing (outer shell/body). In remanufac- turing, the part must be completely disassembled, cleaned and examined for wear and breakage. Worn out, missing or non-functioning components are replaced with new or rebuilt components, as deemed necessary. Electrical parts are tested separately for voltage and receptivity. A er all work is done, the part is reassembled and tested for compliance with performance specifi cations. However, a rebuilt part normally costs 40-55 percent of the cost of a comparable new one and customarily carries the same warranty. In our case, DPA's standard warranty for all injectors sold within North America is guaranteed for one year or 100,000 miles. For injectors used overseas, this warranty is reduced to six months, due to the lower quality of diesel fuel used. As a result, the use of remanufactured products in the market has increased steadily for those items that are rebuildable, such as injectors, turbochargers, fuel pumps etc. ese, and many other remanufactured parts, enjoy a major share of the market now. The concept of remanufacturing A remanufactured product is o en the term used to describe a worn-out/broken/ used product that has been restored to its original specifi - cations or has been upgraded to meet the OEM's perfor- mance specifi cations. Hence, remanufacturing not only promotes the multiple reuse of materials, but it also allows for the steady upgrading of quality and functions of products, and does this without the need to manufacture completely new products and throw away used ones. e used/worn-out/ broken products that enter the remanufacturing process are o en called "cores." Many defi nitions exist for remanufacturing, but most are variations on the same basic idea of product rebuilding. However, when dealing with DPA remanufactured injec- tors, the most accurate term to use is Newalized TM , in which the remanufacturing process is defi ned as follows: "Remanufacturing is an industrial process whereby products referred to as 'cores' are restored to useful life. During this process, the core pass through a number of remanufacturing steps, e.g. inspection, disassembly, cleaning, part replacement/ refurbishment, reassembly, and testing, to ensure they meet the desired product standards." What happens to the cores DPA receives? • Cores are received at our core receiving department. • Each core is visually inspect- ed fi rst, to detect any damaged and/or missing components. Items such as a bad solenoid, cracked nozzle/tip, broken spring, cracked body or pitted body are reported to the cus- tomer, as these may deem an injector core useless. • e cores are completely dis- assembled, and non-reusable components, such as springs, but- tons, o-rings, seat, fi lter or screen are discarded. • e remaining injector com- ponents are put through electronic ultrasonic cleaning equipment from such companies as Safety-Clean and Sunnen. • Each critical component, such as the nozzle/tip and plunger, is inspect- ed and tested to make sure it is still in good condition. • e nozzle/tip is then re- ground, lapped, and extrude honed using Kennametal's most sophisticated equipment. is equipment is designed to re-hone the holes inside the tip to their original size (OD) and angle, ensuring that holes are completely open and free of any contaminants and small particles or burrs. • e plungers are re- chromed, lapped and re-honed back to the original specifi ca- tions. • e solenoid/coil is tested to make sure the electricity cur- rent received is accurate, per the injector's engine applica- tion/model. Remanufacturing Injector CAT. 3126 being tested and calibrated Diesel Parts of America I DA U N I V E R S A L S e p te m b e r - O c to b e r 2 0 1 4 34